Overmolded Magnesium

ABSTRACT

A method of manufacturing an assembly, including a structural member and an appearance feature formed therealong, is provided utilizing first and second molds. The method includes the steps of: injecting magnesium into the first mold to form the structural member; removing the structural member from the first mold; placing the structural member in the second mold; and injecting thermoplastic material into the second mold to overmold the appearance feature along a portion of the structural member.

BACKGROUND

The invention relates to structural components formed from magnesium andincluding appearance features overmolded thereto, and to a method formanufacturing these structural components.

It is well-known in the art to provide structural components or runningboards for assisting individuals in either entering and exiting oraccessing motor vehicles having a high ground clearance. These runningboards may include at least one mounting bracket for mounting a step orplatform alongside the motor vehicle. Various appearance features, suchas covers, step mats, end caps, shields, and the like, are formed asseparate elements that are secured to the mounting bracket and/or thestep or platform. Each of these appearance features typically requiresindividual attachment to the mounting bracket or platform, takes upvaluable packaging space, and limits styling flexibility.

SUMMARY

According to one aspect of the invention, a method of manufacturing anassembly, including a structural member and an appearance feature formedtherealong, utilizes first and second molds. The method includes thesteps of: injecting magnesium into the first mold to form the structuralmember; removing the structural member from the first mold; placing thestructural member in the second mold; and injecting thermoplasticmaterial into the second mold to overmold the appearance feature along aportion of the structural member.

According to another aspect of the invention, a method of manufacturinga running board assembly, including a platform, a mounting bracket, andan appearance feature, via first and second molds, includes the stepsof: injecting magnesium into the first mold to form the platform;removing the platform from the first mold; attaching the mountingbracket to the platform; placing the platform and the mounting bracketattached thereto into the second mold; and injecting thermoplasticmaterial into the second mold to overmold the appearance feature alongat least one of the platform and the mounting bracket.

According to yet another aspect of the invention, a running boardassembly for a motor vehicle includes a structural member including aplatform formed from injection molded magnesium and adapted to bemounted to the motor vehicle. The platform includes a stepping surfaceextending between opposing ends. The running board assembly alsoincludes an appearance feature injection molded onto the platform.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be readily appreciated as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a running board assembly including aplatform, formed from magnesium, and a mounting bracket with appearancefeatures overmolded thereto according to one embodiment;

FIG. 2 is a section view of the running board assembly including theplatform and the mounting bracket;

FIG. 3 is a perspective view of a running board including a tubularmember and appearance features overmolded therealong;

FIG. 4 is a cross-sectional view taken along lines 4-4 in FIG. 3;

FIG. 5 is a cross-sectional view of the tubular member wherein theappearance feature is a step mat; and

FIG. 6 is a cross-sectional view of a mold for receiving the runningboard and mounting brackets for overmolding appearance features thereto.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring to FIG. 1, an assembly, generally shown at 10, includes atleast one structural member 12, 14 and at least one appearance featureovermolded to the at least one structural member 12, 14. Each structuralmember 12, 14 is formed from injection molded magnesium. Each structuralmember 12, 14 is, therefore, a lightweight but generally rigid member.It is appreciated that the assembly 10 may be any of various parts orcomponents for use in numerous industries.

In one embodiment of the invention, the assembly 10 is a running boardassembly and the structural members 12, 14 are a platform and mountingbrackets respectively. The platform 12 of the running board assembly 10includes a stepping surface 16 for supporting individuals entering orexiting a motor vehicle. The platform 12 extends longitudinally betweena pair of opposing ends 18, 20, and laterally between an inboard end 22and an outboard end 24.

The mounting brackets 14 are fixedly secured to the platform 12 andadapted for attachment to the motor vehicle. The mounting brackets 14mount, therefore, the platform 12 to the motor vehicle. It isappreciated that the platform 12 and the mounting brackets 14 may beformed as an integrally formed single piece or as separate piecesfixedly secured to one another. In the current embodiment, the runningboard assembly 10 includes a pair of mounting brackets 14 spaced apartfrom one another. Each mounting bracket 14 includes an outboard facingsurface 26 and an inboard edge 28.

The running board assembly 10 further includes at least one appearancefeature overmolded to a portion of the platform 12 and/or the mountingbrackets 14. Each appearance feature is formed from a thermoplasticmaterial. One appearance feature is an end cap 30 overmolded to theplatform 12 at each opposing end 16, 18 thereof. The end caps 30 providea finished look to the opposing ends 18, 20 of the platform 12.

Another appearance feature is a shield 32 formed along the outboardfacing surface 26 of the mounting brackets 14. The shield 32 may also beformed along the outboard end 24 of the platform 12, as shown in FIG. 2.The shield 32 protects the platform 12 and the mounting brackets 14 fromdamage from stone pecking as may occur during normal operation of themotor vehicle.

Another appearance feature for the platform 12 is a step mat, generallyindicated at 34, which is formed in a longitudinal direction along thestepping surface 16. In the current embodiment, the step mat 34 includesa plurality of tread portions 36 each spaced apart from one another in alateral direction. The step mat 34 provides traction to individualsstepping onto the platform 12.

Referring to FIGS. 3 and 4, in another embodiment the structural member12′ of the running board assembly 10′ is a tubular member extendingbetween inboard-facing ends 38, 40. The tubular member 12′ includes thestepping surface 16′ extending longitudinally between the opposing ends38, 40. In the current embodiment, the appearance feature is a cover 42overmolded to the stepping surface 16′. The cover 42 extendscontinuously along the stepping surface 16′ in a lateral direction. Inanother embodiment, shown in FIG. 5, the appearance feature is the stepmat 34′ including the plurality of tread portions 36′ formed along thestepping surface 16′ of the tubular member 12′ and spaced apart from oneanother in a lateral direction.

First and second molds are utilized in a method of manufacturing theassembly 10, 10′. The first step in the method for manufacturing theassembly 10 is forming the structural member 12 by injection moldingmagnesium into the first mold. The structural member 12 is removed fromthe first mold. The structural member 12 is placed in a second mold 44.The second mold 44 includes a lower mold half 46 and an upper mold half48 movable relative to the lower mold half 46. The second mold 44 isclosed and thermoplastic material is injected therein. As a result, thethermoplastic material is formed into one or more appearance featuresovermolded to a portion of the structural member 12. A finishingoperation may be conducted on the structural member 12 either after thestep of forming the structural member by injection molding magnesium iscompleted or after the one or more appearance features are overmoldedonto the structural member 12.

In a method according to another embodiment of the invention, a methodof manufacturing the running board assembly 10 begins with the step ofinjecting magnesium into the first mold to form the platform 12. Theplatform 12 is then removed from the first mold. The mounting bracket 14is attached to the platform 12 either by integrally molding the mountingbracket 14 with the platform 12 or by attaching the mounting brackets 14to the platform 12 after molding thereof. The platform 12 and themounting bracket 14 are placed in the second mold. The upper mold half48 is closed against the lower mold half 46 and thermoplastic materialis injected into the second mold to overmold the at least one appearancefeature to at least one of the platform and mounting bracket.

It is appreciated that the above-described methods could be utilized toprovide appearance features with various colors, materials, andtextures. The running board assemblies 10, 10′ manufactured according tothese embodiments can be produced at a lower cost due to reducedcomplexity, fewer part numbers, and lower labor requirements. Moreover,quality is improved through the use of fewer components, less variablesand variation, and little or no warpage concerns. As an added benefit,there is greater flexibility with regard to overall styling.

The invention has been described in an illustrative manner. It is to beunderstood that the terminology, which has been used, is intended to bein the nature of words of description rather than of limitation. Manymodifications and variations of the invention are possible in light ofthe above teachings. Therefore, within the scope of the appended claims,the invention may be practiced other than as specifically described.

1. A method of manufacturing an assembly, including a structural memberand an appearance feature formed therealong, utilizing first and secondmolds, the method comprising the steps of: injecting magnesium into thefirst mold to form the structural member; removing the structural memberfrom the first mold; placing the structural member in the second mold;and injecting thermoplastic material into the second mold to overmoldthe appearance feature along a portion of the structural member.
 2. Amethod as set forth in claim 1 wherein the step of injectingthermoplastic material into the second mold to overmold the appearancefeature along a portion of the structural member includes forming acover for the structural member.
 3. A method of manufacturing a runningboard assembly, including a platform, a mounting bracket, and anappearance feature, via first and second molds, the method comprisingthe steps of: injecting magnesium into the first mold to form theplatform; removing the platfoim from the first mold; attaching themounting bracket to the platform; placing the platform and the mountingbracket attached thereto in the second mold; and injecting thermoplasticmaterial into the second mold to overmold the appearance feature alongat least one of the platform and mounting bracket.
 4. A method as setforth in claim 3 wherein the step of attaching the mounting bracket tothe platform occurs at the same time as the step of injecting magnesiuminto the first mold to form the platform such that the platform and themounting bracket are formed as one piece.
 5. A method as set forth inclaim 3 wherein the step of attaching the mounting bracket to theplatform occurs subsequent to the step of injecting magnesium into thefirst mold to form the platform.
 6. A method as set forth in claim 3wherein the step of injecting thermoplastic material into the secondmold to overmold the appearance feature along at least one of theplatform and mounting bracket includes forming a cover for the platform.7. A method as set forth in claim 3 wherein the step of injectingthermoplastic material into the second mold to overmold the appearancefeature along at least one of the platform and mounting bracket includesforming a shield along a portion of at least one of the platform and themounting bracket.
 8. A method as set forth in claim 3 wherein the stepof injecting thermoplastic material into the second mold to overmold theappearance feature along at least one of the platform and mountingbracket includes forming a step mat including a plurality of spacedapart tread portions along the platform.
 9. A running board assembly fora motor vehicle, said running board assembly comprising: a structuralmember including a platform formed from injection molded magnesium andadapted to be mounted to the motor vehicle, said platform having astepping surface and extending between opposing ends; an appearancefeature injection molded onto said platform.
 10. A running boardassembly as set forth in claim 9 including a mounting bracket fixedlysecured to said platform and directly mountable to the motor vehicle.11. A running board assembly as set forth in claim 9 wherein saidappearance feature is a step tread disposed along said stepping surfaceof said platform.
 12. A running board assembly as set forth in claim 9wherein said appearance feature is a cover formed along said steppingsurface of said platform.
 13. A running board assembly as set forth inclaim 9 wherein said appearance feature is an end cap formed along eachopposing end of said platform.
 14. A running board assembly as set forthin claim 9 wherein said appearance feature is a shield formed along atleast one of said platform and said mounting bracket.